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ABSTRACT
The use of new digital I&C systems in the design of new nuclear power plants, as well as the modernization of
existing facilities, implies relevant changes in the control room design. New I&C systems provide new features
that affect the control room operating concept. Therefore, a detailed analysis is required to take into
consideration all the operating and human factors aspects. Based on Tecnatom experience in the field, this
article presents the methodological approach used as well as the most relevant aspects of this kind of project.
1. INTRODUCTION
The Instrumentation and Control (I&C) of the latest nuclear power plants is based on the use
of digital technology, distributed control systems and the integration of information in data
networks (Distributed Control and Instrumentation Systems). This has a repercussion on
Control Rooms (CRs), where the operations and monitoring interfaces correspond to these
systems.
These technologies are also used in modernizing I&C systems in currently operative nuclear
power plants. The new interfaces provide additional capabilities for operation and
supervision, as well as a high degree of flexibility, versatility and reliability. An example of
this is the implementation of solutions such as compact stations, high level supervision
screens, overview displays, computerized procedures, new operational support systems or
intelligent alarms processing systems in the modernized Man-Machine Interface (MMI).
These changes in the MMI are accompanied by newly added SW controls and new solutions
in automation.
Incorporation of these systems in control rooms substantially modifies the interface between
the operator and the plant systems, compared to the classical configuration of the majority of
current control rooms. In many cases the conceptual model of operations is also altered.
For adequate licensing, the design process of new control rooms requires an in-depth and
detailed analysis of Human Factors Engineering (HFE) in order to achieve a design of the
interface between the operator and the plant systems that ensures, allows for and optimizes
safe operation and supervision by the operating personnel under any plant operating
condition, be it in normal operation, during incidents, in the event of plant or I&C equipment
failure, or during emergency operation.
Tecnatom has been leading various projects in this field for several years, both in Asian
countries and in the United States, using in all cases international standards from which
Tecnatom own methodologies have been developed and optimized. The experience acquired
in applying this methodology to the design of new control rooms is to a large extent
applicable also to the modernization of current control rooms.
In general, and unlike in the case of new facilities design, processes for modernizing control
rooms are projects that usually move forward slowly, outage after outage, with the operator
interface and control being modified to a different extent. As the individual impact of each
modification in the interface is not usually important, and modifications tend to be developed
over the years, it is more likely that in this case the analyses of impact on the interface would
be limited, that they would be performed individually and that they lack of an overall long-
term vision. However, this impact is clear in many plants and, considering a period of four or
five refueling outages, substantial changes may be observed in the way in which the plant is
operated and supervised.
An adequate design of the interface between the operator and the systems will facilitate safe
operation, contribute to the prompt identification of problems and help in the distribution of
tasks and communications between the different members of the operating shift.
The design of new nuclear power plant control rooms constitutes a project of enormous
technical and organizational complexity. On the technical level, all the plant systems and their
components have to be analyzed in great detail, taking into account their operation and
supervision requirements under all possible plant conditions. As regards organization, it is
important that all the engineering organizations participating in the design of the plant
systems, and all those responsible for plant operation were connected; and that their work
could be adequately coordinated. All this must be incorporated in a complex overall planning
of plant design and construction, with the availability of the reference documentation
constituting one of the most critical aspects.
The design of new control rooms must necessarily combine two fundamental aspects:
Capacities provided by the technology used in I&C systems. These systems, based on
the use of digital technology, offer interesting possibilities for the development of the
new Man-Machine Interface (MMI) of these control rooms, which often will be
completely software-based.
The application of a Human Factors Engineering (HFE) programme ensuring a
correctly designed and implemented MMI, increasing human reliability and
2.1. Human Factors Engineering (HFE) in the design and implementation of new
control room MMI’s
Design of the new control rooms MMIs begins with the definition of the objectives to be met
by the control room. This is followed by the initial establishment of the operating principles
that describe the practices and characteristics of the MMI necessary to fulfill these objectives.
The design of the control room MMI will be based on the above, with consideration given to
the possibilities offered by I&C systems.
The use of methodologies ensuring an adequate application of HFE will allow for an
optimum MMI design. These methodologies are based on international standards such as IEC
60964, NUREG-0800, NUREG-0711, NUREG-6393, NUREG-6400, IEC-6177, ISO-9241
and NUREG-700.
These methodologies are used during the MMI Specification, Design, Testing and
Implementation phases.
2.2. Methodologies for the implementation of Human Factors Engineering in the design
of new control rooms
Figure 2 below depicts the final representation of the stand-up panel and sit-down console
profiles for the Fuqing NPP control room, made in accordance with ergonomic considerations
and HFE guidelines for comfortable and safe operation.
The next step consists in harmonizing the design of the displays or screens that constitute the
basis for normal plant operation with the hardware (hardwired) instruments that are installed
on the panels and consoles for redundancy, back-up or safety reasons.
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Conventional hardware instrumentation and its arrangement in the different panels and
consoles are likewise determined and specified. Figure 4 below shows the mosaic design of
the emergency panel of the control room at the Hainan plant (China) by way of an example.
The design also includes all the additional equipment required by the operator for the
performance of administrative tasks and internal and external communications.
Most operating nuclear power plants are undertaking projects for the modernization of those
of their I&C systems that have an important impact in the control room, either because of the
obsolescence of the current equipment, the incorporation of equipment facilitating operation
and supervision or the fact that the plant is facing lifetime extension.
These projects, which have already begun to alter the appearance of our control rooms, will
undoubtedly grow in number. It is reasonable to imagine that the control rooms that the plants
In modernization processes, changes in the I&C systems and MMI carried out step by step
(e.g., turbine control, reactor control, FWCS control,…), in which each change is
incorporated in the control room individually without considering the characteristics of the
MMI, usually pose integration problems.
Furthermore, if they are performed individually, without taking into consideration the overall
modernization plan, they will often be arranged and located in the control room attending
only to space constraints, this possibly penalizing the tasks of the operator. In addition, as the
modernization process continues, the changes implemented in this way may even degrade the
effectiveness of the control room, having a negative impact on operation that might imply the
need for it to be re-designed, with the associated costs that this would imply.
An overall view prior to making the changes of what the MMI will be like at the end
of the process, and in each of the phases of modernization.
Guaranteed consistency and integration of the changes to the MMI over time.
Assurance that whatever HFE problems might exist have been solved.
Improvement of the existing MMI, making appropriate use of the technology
associated with new I&C systems.
Assurance that the MMI meets the regulatory requirements, both at the end of
modernization and in the intermediate configurations.
Involvement of the operating personnel. In order for the design of the MMI to be
effective, it is necessary for it to take into account the capabilities and experience of
the operator (“human centered” concept). Each plant has its own concept of operation,
based on the practices developed as a result of the modifications performed over the
lifetime of the plant and on the experience of the operators.
Capacities of the new technologies available for the MMI. In order to define the
concept of the definitive MMI, it is necessary to understand what a control room with
a modern MMI based on digital technology is like and the differences in the way it is
operated compared to a traditional interface. Aspects such as operating stations based
on a software MMI, the use of overview displays, the integration of 1E and non-1E
software controls, the advanced treatment of alarms or the management of I&C and
MMI failures must be considered.
Application of Human Factors Engineering. In order to ensure the adequate
application of HFE in the development and subsequent implementation of the Plan, a
combination of factors is required, such as the following:
It is also important to describe how the status of the plant systems and components will be
watched over, how an alert will be issued in the event of conditions requiring operator
intervention, how incidents will be diagnosed, how activities will be planned to solve
incidents, how the components and systems will be controlled, how the different members of
the operating team will be coordinated and how operations will be supervised.
This concept may vary depending on the functionalities and degree of automation of the new
I&C systems.
The concept of the modernized control room MMI underlines those aspects that provide a
view of the modernized MMI coherent with the operating concept. The experience gleaned in
the design of solutions for the MMI in new control rooms is of great use.
The following are examples of aspects to be analyzed:
Changes in the type and structure of the displays that supply information to the
operating team and undertake its distribution in the control room.
Installation of an overview display. Is it necessary? What type of information would it
display?
Integration of “traditional” indicators and registers in information displays.
Implementation of software controls. To what extent will they replace the
“traditional” controls?
Hardware controls that will be maintained and others that will be implemented as a
back-up in the event of software MMI failure.
Alarms system. Will there be changes in the way the alarms are displayed? Will
filtering and prioritization criteria be applied?
Distribution of panels, consoles and operations stations in the control room.
The guidelines for the process of MMI implementation describe the HFE programme to be
applied in modernizing the MMI. They allow for the adaptation of a generic HFE
programme based on international standards (for example NUREG-0711) to the specific
They are used to classify the modernization of the MMI of each system from the point of
view of HFE and depending on the level of risk. By means of this classification, a level of
application of the HFE programme is associated with each modernization, in keeping with the
dimension of the modification.
It is important that the scope of HFE activities is optimized and planned efficiently, in order
to prevent the cost of such activities from becoming burdensome in comparison to the cost of
modernization, and the specific methodologies for the modernization of control rooms have
been oriented in this respect.
4. CONCLUSIONS
Given the enormous capacities of new digital I&C systems, the detailed analysis of human
factors engineering takes on a special relevance, the objective being to determine the ideal
interface for the operator taking into account the tasks to be addressed under any plant
operating condition. This interface, jointly defined on the basis of the operating concept, will
define the design of the new control room or of the modernization in the case of an existing
control room.